Molten metal level control in continuous casting

ABSTRACT

This invention is directed to the process and system for controlling the level of molten metal in a plurality of vertically oriented, continuous or semicontinuous casting units, particularly electromagnetic casting units. The flows of molten metal to the individual casting units are adjusted automatically in response to a control set point signal from a master controller in order to maintain essentially the same molten metal level in all of the casting units. Improved startup and termination procedures are also given.

This is a Division of application Ser. No. . 266,788 filed May 26, 1981,now U.S. Pat. No. 4,498,521.

BACKGROUND OF THE INVENTION

This invention relates to the molten metal level control in vertical,continuous or semicontinuous casting assemblies and particularly to suchcasting units wherein an electromagnetic field generated by an annularinductor surrounding the column of molten metal is used to shape thesolidifying metal.

Aluminum ingots or billets which have been continuously orsemicontinuously direct chill (DC) cast in conventional, open ended,tubular molds are usually characterized by various degrees of surfacedefects such as cold folds, liquations, hot tears and the like, whichresult primarily from the contact between the mold and the solidifyingembryonic metal shell. Conventional DC cast ingots or billets are alsocharacterized by considerable alloy segregation at the surface due tothe sequential steps of initial cooling and partial solidification ofthe molten metal surface from contacting the chill surfaces of the moldbore, the reheating of the metal surface after the metal contracts awayfrom the mold bore and then the final solidification of the molten metalby conduction toward the direct application of coolant. Theconventionally DC cast ingots or billets usually require scalping toremove both the surface defects and the alloy impoverished zone adjacentto the surface before subsequent fabrication such as rolling, forgingand the like.

Electromagnetic casting is quite similar to conventional DC castingexcept that, instead of the tubular shaped mold used in the conventionalprocess, an annular inductor is employed to generate an electromagneticfield around the column of molten metal which in turn develops radialpressure on the column of molten metal sufficient to control the shapethereof until the metal is solidified into its final shape by the directapplication of coolant. In the operation of electromagnetic castingunits, no contact is made with the embryonic metal shell duringsolidification, so the aforementioned surface defects are for the mostpart eliminated. Moreover, due to the lack of contact between theembryonic metal shell and a chill surface of a mold bore, there isessentially no alloy impoverished zone adjacent to the ingot or billetsurface and thus the electromagnetically cast metal is very homogeneousthroughout its entire cross section. There is usually no need to scalpthe electromagnetically cast material prior to fabrication and, as anadded feature, the homogeneous structure reduces considerably oreliminates the edge cracking characteristic of conventional DC castingot during hot rolling.

The electromagnetic field in EM casting is produced by a ring-typeinductor and the interaction of the electromagnetic field generated bythe inductor with the eddy currents induced in the molten metal withinthe inner peripheral area of the inductor generate the electromagneticpressure which controls the cross-sectional shape of the solidifyingmetal. The radial force components control the lateral position ofmolten metal and nothing contacts the solidifying molten metal untilcoolant is applied to the metal surface as it emerges from the bottom ofthe inductor. Solidification of the metal is effected primarily by theaxial conduction of heat away from the molten metal toward the portionof solidified metal on which the coolant is applied.

The inductor is preferably powered by a high frequency electrical source(e.g. 500 to 15000 cycles per second) because at the higher frequenciesthe induced currents in the molten metal concentrate at the surface ofthe solidifying metal (commonly termed "skin effect") so there is verylittle turbulence caused in the body of the molten metal.

Further information on the principles of electromagnetic casting can befound in U.S. Pat. No. 2,686,864 (Wroughton et al) USSR Inventor'sCertificate No. 233186 and U.S. Pat. Nos. 3,467,166; 3,605,865;3,646,988; 3,702,155; 3,773,101; 3,985,179 and 4,004,631.

In order for ingot or billet to be EM cast with constant cross-sectionaldimensions along the axial length thereof, the radial component of theelectromagnetic pressure must continually be in a dynamic equilibriumwith the hydrostatic pressure of the molten metal. Exercising thecontrol necessary for the dynamic equilibrium is considerably moredifficult than it first appears because minor changes in theelectromagnetic field, in the drop rate, or in the height of moltenmetal can have a significant effect on the cross-sectional dimensions ofthe resultant ingot or billet. Care must be exercised, particularlyduring startup, because a localized pressure of molten metal can exceedthe radial electromagnetic pressure resulting in excursions of moltenmetal over the bottom block which, when solidified, resemble icicles onthe butt end of the ingot or billet. While it is difficult enough tocast one ingot or billet having constant cross-sectional dimensionsalong its length, it becomes even more difficult to exercise suchcontrol when a plurality of ingots or billets are cast at the samecasting station.

Several schemes have been developed in an attempt to overcome thedimensional control problems but none appear to have been widelyaccepted. In U.S. Pat. No. 4,014,379 the electrical current level to theinductor is controlled in response to deviations sensed in the height ofthe molten metal in the inductor. Similarly, although apparently limitedto copper, in U.S. Pat. No. 4,161,206 the electrical current to theinductor is controlled in response to deviations in the distance betweenthe inner surface of the inductor and the vertical surface of the columnof molten metal. In both cases the electrical current level in theinductor is varied to adjust the electromagnetic pressure to compensatefor any differences between the distance measured and that desired.

Although these prior processes may control the dimensions of the ingotor billet to a certain extent, the dimensional control is believedconsiderably less accurate than that desired. Moreover, these processesby themselves are not readily amenable to controlling theelectromagnetic casting of a plurality of ingots or billets in a singlecasting station. It is to these problems that the present invention isdirected.

DESCRIPTION OF THE INVENTION

This invention is directed to a method for controlling the level ofmolten metal in a plurality of vertically oriented continuous orsemicontinuous casting units and particularly such casting units inwhich a radial pressure generated by an electromagnetic inductorcontrols the shape of the molten metal until it solidifies into itsfinal shape.

In accordance with this invention, the flow of molten metal to eachcasting unit is controlled so that the level of molten metal in eachcasting unit is maintained in essentially the same plane throughout mostof the cast. To facilitate this control, each of the casting units isaccurately fixed to a table or similar support structure so that theinductors or molds are on the same level. The support structure orstructures for the bottom blocks are adapted so that all of the ingotsor billets are dropped at the same rate.

The level control in accordance with the invention is effected bysensing the molten metal level in each of the casting units, generatingsignals representing each of the molten metal levels sensed andcomparing these individual signals with a set point signal from a mastercontroller representing the desired molten metal level in all of thecasting units. If there is a predetermined difference between the signalrepresenting the level sensed in a particular unit and the signalrepresenting the desired level, the flow of molten metal to thatparticular casting unit is automatically regulated as needed to bringthe molten metal level in that particular casting unit to the desiredlevel. During the period of control after startup, the level of moltenmetal in each of the individual casting units generally should not varyby more than 0.10 inch (0.25 cm), preferably less than 0.05 inch (0.13cm). Additionally, after the initial startup period, the level of moltenmetal in all of the inductors at the same casting station preferablyshould not vary by more than 0.10 inch (0.25 cm) from each other. Ifthese limits are not maintained, significant variations can be obtainedin cross-sectional dimensions along the length of individual ingots orbillets and between the cross-sectional dimensions of ingots or billetscast in the same drop.

Startup of a plurality of EM casting units presents a most difficultproblem because the molten metal in all of the EM casting units must bebrought up to the same specified level before the bottom blocks begin todrop without significant freezing of molten metal in the transfer troughor in any of the casting units and without any significant excursions ofmolten metal over the edge of the bottom block which is positionedwithin the inductor at the start of the cast. The casting assembliesfarthest away from the molten metal source may have a tendency to freezeup first so the flow of molten metal to those casting units farthestaway from the molten metal source is greater than those closer to themetal source. Preferably, all of the casting units are choke fed, i.e.the flow through the down spout to the casting unit is less than maximummolten metal flow, at all times during the cast to allow some measure ofcontrol.

The initial molten metal flow rates to the casting units at startup areset relatively high in comparison to the remainder of the cast and canbe manually or automatically controlled. However, in accordance with oneembodiment of the invention, the automatic molten metal level controlprocedure is initiated when the molten metal level in any one of thecasting units reaches a predetermined level. In this automaticprocedure, a molten metal level set point signal for all of the castingunits is generated by a master controller. The signal increases withrespect to time and preferably is a ramping set point. The fill ratenecessary to meet the increasing molten metal level required by the setpoint is less than the initial metal flow rates to the casting units sothat all of the units can catch up to the required level. Once the metallevel in each casting unit reaches the required level it is controlledto the increasing set point to the final desired level. Preferably, theincreasing or ramping set point control signal has two or more stageswith the rate of change of level with respect to time being less in thelatter stages than the initial stage in order to minimize overshootingthe final desired molten metal level. It is preferred to start thebottom block descent just before the molten metal level in all of thecasting units reaches the final desired level. A suitable time would bewhen the metal level is about 0.25 to 0.50 inch (0.64 to 1.27 cm) fromthe final level.

The final molten metal level is automatically maintained throughout thecast within the limits previously mentioned. At the end of the cast themolten metal source is plugged off and the molten metal in the trough isallowed to drain into the casting assemblies until the specified metallevel in any of the casting units can no longer be maintained. At thistime the trough is lifted, allowed to drain completely into a containerand then removed from the casting area so that the table can be liftedor otherwise moved and the ingots or billets can be removed from thecasting pit. When the trough is lifted for draining, those casting unitscloser to drain container will receive more molten metal than thosefurther away so it is desirable to reduce the levels of molten metal inthose casting units closer to the drain before the end of the cast sothat all of the ingots and billets are of approximately the same length.The change in molten metal head height is relatively small, e.g. lessthan an inch (2.54 cm) and for large sheet ingots typically 0.1 to 0.5inch (0.24 to 1.27 cm).

At the end of the cast coolant application to the surface of the ingotsor billets at the exit or discharge end of the inductors or molds iscontinued until the solidification is complete and the end of the ingotor billet is discharged from the inductor or mold.

The level control described herein is suitable for use in a wide varietyof casting units. In the operation of EM casting units, the height ofmolten metal within the inductor is integrally related with theelectromagnetic pressure generated by the electromagnetic field. In apreferred embodiment the electromagnetic field and resultant pressure ismaintained constant with the height or level of the column of moltenmetal in the inductor being the controlled variable. This controlstrategy requires the inductor current to be at essentially the sameamplitude and frequency in each of the casting units. Other controlstrategies are possible.

Reference is made to the drawings which illustrate the invention ingreater detail.

FIG. 1 is a perspective view, partially in section, of an EM castingunit.

FIG. 2 is a top view of several EM casting units at a single castingstation.

FIG. 3 is a side view, partially in section, of two EM castingassemblies taken along the lines III--III in FIG. 2.

FIGS. 4 and 5 are side and top views of the valve actuating arm assemblywhich regulates the flow of molten metal from the trough into the moldor inductor.

FIG. 6 is a schematic drawing of the molten metal level control system.

FIG. 7 is a graph illustrating molten metal head height control at thestartup of casting. In the drawings all corresponding parts are giventhe same number.

With particular reference to FIGS. 1-3, the electromagnetic castingapparatus generally comprises a coolant jacket-inductor assembly 10, abottom block assembly 11 and a molten metal feeding assembly 13.

The coolant jacket-inductor assembly 10 comprises an electromagneticinductor 14 as the innermost wall of the assembly which is fixed in asealed relationship with top member 15, bottom member 16 and backwall17. A baffle wall 18 adjacent to the backwall of inductor 14 andconcentric therewith divides the interior of the assembly 10 into twoannular coolant chambers 19 and 20. The baffle member 18 is providedwith conduit 21 for directing coolant from chamber 19 to chamber 20. Thecoolant from chamber 20 passes through the discharge conduits 22provided in the lower portion of inductor 14 onto the solidifying ingotor billet 23. The coolant jacket members 15, 16, 17 and 18 arepreferably made from nonmetallic materials such as suitable plasticmaterials.

The upper portion 25 of electromagnetic inductor 14 is preferablyinclined away from the vertical axis of the coolant jacket-inductorassembly 10 as shown to reduce and to control more accurately theelectromagnetic forces on the upper part of column 26 of the moltenmetal in accordance with U.S. Pat. No. 3,985,179 (Goodrich et al). Theangle of the surface 25 with the vertical axis of the assembly 10depends upon such factors as the metal head, the size of the ingot orbillet, and the like. Usually the desired angle is empiricallydetermined and ranges from about 10° to 50°.

The inductor 14 is metallic, e.g. copper or aluminum, and is preferablyprotected from accidental contact with the molten metal by a nonmetalliccoating or surface (not shown) which does not significantly effect theelectromagnetic field generated by the inductor.

The coolant jacket-inductor assemblies 10 are attached in a suitablemanner (not shown) to the casting table 27, which may be hinged on oneside or mounted on rollers so that the table 27 and the attachedassemblies 10 can be moved out of the way at the end of the cast toallow removal of the cast ingots or billets 23 from the casting pit.

The bottom block assembly 11 is best illustrated in FIG. 3. As shown,each of the bottom blocks 30 is supported by and attached to the sametable or support surface 31 by means of pedestal 32 in order toeliminate any variation in drop rate between the casting units. Thelowering of support surface or platen 31 should be smooth and be done ata uniform rate, because any sudden movements can detrimentally affectthe size and shape of the ingot or billet. The bottom blocks 30 can beindividually lowered, if desired, but it is more convenient to supportthem all on the same platen 31 as is done conventionally and lower theplaten 31 to lower all of the bottom blocks.

The molten metal feeding assembly 13 comprises feed trough 35,preferably formed from suitable nonmagnetic material such as stainlesssteel, which has a refractory lining 36. Molten metal 37 is distributedto a plurality of EM casting assemblies 10 by means of downspouts 38which protrude into the inner peripheral area of inductors 14. Moltenmetal flow to the inductor 14 is controlled by flow control pin or valveplug 40. The lower end 41 thereof is adapted to seat in the recess 42provided in the upper portion of downspout 38.

As shown more clearly in FIGS. 4 and 5 the upper part 43 of flow controlpin or valve plug 40 is preferably threaded and is provided with acorresponding threaded collar 44 for minor adjustments in the positionof pin or plug 40 with respect to the recess 42.

The collar 44 has arms 45 which are seated in the recesses 46 providedin yoke 47 of lever arm 48. The lever arm 48 is pivoted at points 49 and50 so that, upon rotation of arm 48 about these points, the flow controlpin 40 is raised or lowered thereby regulating the flow of molten metalto the inner periphery of inductor 14. The end of arm 48 is providedwith a balancing weight 51.

The movement of lever arm 48 is effected by the rotation of cam 55 whichis driven by motor or rotary actuator 56 in response to a suitablecontrol signal. The cam 55 preferably has the shape of a spiral ofArchimedes as shown in the drawing because with such a shape each unitof angular rotation of cam 55 will provide an equal unit of lineardisplacement of the lever arm 48 and thus the flow control pin 40.

Each pin or plug 40 is preferably preset remotely via the motor orrotary actuator 56 before casting begins to provide a predeterminedvalve opening. Those casting units farthest away from the molten metalsource should have greater openings and thus greater molten metal flowthan those casting units closest to the molten metal source. Theseadjustments compensate for the initial flow to the casting units closerto molten metal source and also help to prevent freeze up before thecasting begins.

Molten metal level sensing in each of the casting units is accomplishedby means of a float 60 which rests on the upper surface 61 of the columnof molten metal 26 within the inductor 14. The float 60 is operativelyconnected by means of rod 62 and connector element 63 to shaft 64 ofdisplacement transducer 65 which provides an output signal representingthe level of molten metal sensed by the float 60. Guide element orbracket 66 is fixed to the side of trough 35 for guiding the verticaldisplacement of rod 62 during casting. Collet 67 is provided on rod 62to stop downward movement of the float 60 during noncasting periods.

The displacement transducer 65 should have a range of about 4 inches andshould be accurate within 0.01 inches (0.025 cm), preferably within0.005 inches (0.013 cm). A suitable transducer is Model 2000 HPA sold bythe Schaevitz Corp. of New York, NY. Although the level sensing andsignal generating unit is primarily described herein as a floatoperatively connected to a linear displacement transducer, it is evidentthat other means can be employed for sensing the level and generating asignal representing the level sensed.

The vertical positioning of the float 60 is very important for theaccurate control of the molten metal level 61 in the inductor 14. Thefloat material generally should not absorb molten metal or impuritiesand it must retain its integrity throughout the cast in order to preventany change in the displacement of the float 60 on the molten metalsurface 61. A suitable material for the float is MARINITE which is alightweight fibrous refractory material (magnesium silicate)manufactured by the Johns Manville Corp.

The trough 35, as shown in FIG. 3, is accurately positioned on thecasting table 27 because the displacement transducer 65 is fixed to thetrough and accurate placement of the transducer is necessary at the timethe trough is put into position to accurately measure the molten metallevel in the inductor 14. The positioning of trough 35 is effected byone or more cone shaped male members 68 at the end 69 of trough 35 whichare adapted to be accurately seated in female receptacles 70. Theopposite end of the trough 35 is accurately fixed to the discharge sideor trough of a filter-degasser unit which is not shown.

The molten metal level control system for all of the casting units,which is shown schematically in FIG. 6, includes a master or supervisorycontroller 80 which provides directions and molten metal level set pointsignal to local controllers 71 associated with each individual castingunit. Each of the local controllers 71 compares the signal representingthe condition sensed e.g. molten metal level, with the signal from themaster controller 80 representing the desired set point and then directscorrective action as required. In order to simplify FIG. 6 only onepartial casting unit is shown. The master controller 80 also can directother activities such as the lowering of the bottom blocks throughcontroller 82 and controlling the flow of coolant.

A suitable controller unit for the master controller 80 is the Model No.484 Modicon controller sold by the Gould Company, Modicon Division inAndover, MA, and suitable local controllers 71 are Electromax III soldby the Leeds & Northrup Co. in North Wales, PA.

During casting, the molten metal level 61 is sensed by float 60 andcauses displacement transducer 65 to generate a signal representing themetal level sensed. The sensed metal level signal is directed to localcontroller 71 which compares the sensed metal level signal with a signalfrom the master controller 80 representing the desired molten metallevel. Any differences will cause the controller 71 to direct a controlsignal to the drive motor or rotary actuator 56 to rotate the cam 55 andthereby raise or lower flow control pin 40 to appropriately regulate theflow of molten metal to the casting unit so that the upper surface 61 ofthe molten metal is maintained at the desired level.

A suitable rotary actuator is Model No. SM-1180 actuator produced andsold by Foxboro/Jordan, Inc., Milwaukee, WI. A Foxboro/Jordan amplifiersuch as Model AD 7530 is usually included to drive the actuator.

The master controller 80 directs the same desired molten metal level setpoint signal to each of the local controllers 71 for the individual EMcasting assemblies so that the metal level in each of the castingassemblies is in essentially the same horizontal plane. Because of this,each of the EM casting units, including each of the inductors, the levelfloats and the displacement transducers must be accurately positioned atthe same relative level. To avoid thermal distortion during casting,which can cause misalignment of casting assembly components, it ispreferred to water cool the trough 35 and the inductor assembly.

The start of EM casting is the most difficult part of the casting tocontrol because the system at the time is not in dynamic equilibrium andmany things can go wrong. A particularly effective startup procedure forthe present invention is shown graphically in FIG. 7. In accordance withthis embodiment of the invention, the flow control plugs 40 arepositioned at the start so that the flow of molten metal is greatest tothe casting units farthest from the molten metal source, to therebyequalize, as much as possible, molten metal flow to all of the units andto minimize freeze up problems. Floats 60 rise as the metal level risesin the bowl shaped bottom blocks 30 positioned within the inductors 14at the start of the cast. When the molten metal level 61 sensed in anyone of the casting units reaches a predetermined initial level, shown aspoint A in FIG. 7, the master controller 80 sends a ramping set pointsignal representing the desired metal level with respect to time (lineAB in FIG. 7) to the individual local controllers 71 to regulate theflow of molten metal to the individual casting units. The position offlow control pin 40 is automatically adjusted by means of the rotaryactuator 56 to provide the metal head height prescribed by the rampingset point signal from the master controller 80. The molten metal levelof the casting unit which initiates the automatic control follows theline AB in FIG. 7 and this casting unit is identified as #1 in FIG. 7.In the operation of the other casting units, shown as #2-5 in FIG. 7,the local controllers 71 adjust the flow control pins 40 to regulate themetal flow in order for the metal levels in casting units 2-5 to catchup to the moving set point. The levels of molten metal in all of thecasting units reach the level required by the ramping set point and arefollowing the same before reaching a predetermined molten metal levelshown as Point B in FIG. 7. At point B the rate of change of the rampingset point signal from the master controller 80 is reduced, concomitantlyreducing the rate of molten metal level increase. This is shown as lineBC in FIG. 7. The metal level in all of the casting units follows thisslower fill rate because it allows the metal levels in the casting unitsto slowly approach the final desired level (point C in FIG. 7) withoutsignificantly overshooting the limit. Bottom block movement is initiatedat a predetermined metal level or time just before the metal reaches thefinal level in all of the casting units in the last stage, e.g. when themetal is within 0.25 inch (0.63 cm) from the final desired level.

Once the molten metal level 61 reaches the final desired level, it isautomatically maintained throughout the cast. Minor adjustments to themolten metal level during the cast can be made by manually commanding anew set point to the local controller 71 via the master controller 80.The control must be tight because any small changes in the molten metalhead height, as previously discussed, will generate significantvariations in ingot or billet dimensions. Preferably, the system shouldinitiate an audio and/or visual alarm if the local controller 71 can notmaintain the molten metal level in the inductor. For safety purposes, itis preferred to program the local controllers 71 to drive the flowcontrol pins 40 closed upon any significant drop in the electromagneticfield. The cast is terminated by shutting off the flow of molten metalfrom the source, either manually or automatically, and allowing themolten metal in the trough to drain into the casting units. Thetermination is initiated at some predetermined point in the process(e.g. based on time or length of cast metals) to provide the ingot orbillet length desired, taking into consideration the amount of moltenmetal remaining in the trough when flow from the molten metal sourceceases. Minor changes in the molten metal levels may be desirable priorto the time the molten metal source is plugged off in order tocompensate for any differences in the amount of molten metal flowing tothe various casting units. Frequently it is found that those farthestfrom the molten metal source receive less metal than those closest whenmolten metal flow from the source is stopped. Coolant application to theingot or billet surface preferably continues until the ends of theingots or billets exit from the discharge ends of the casting units andthe ingot has completely solidified.

The system and method of the invention allows for very close control ofthe ingot or billet size and shape. For example when EM casting 5 ingotsnominally 19×43×138 (48.3×109.2×350.5 cm) in size, thc maximum deviationof the largest cross-sectional dimension found along the length of theingot (excluding normal butt swell) was less than 0.1 inch (0.25 cm).Between ingots the maximum deviation was less than 0.25 inch (0.64 cm).

It is obvious that various modifications can be made to the inventionwithout departing from the spirit thereof and the scope of the appendedclaims.

1. In a system for controlling the level of molten metal in a pluralityof vertically disposed continuous or semicontinuous conventional DCtubular or EM casting units having feed and discharge ends and whereineach of the said casting units includes a means for shaping a column ofmolten metal during the solidification thereof, means for directingmolten metal to the feed end of the metal shaping means and bottom blockassembly means for supporting and lowering the solidified or partiallysolidified ingot or billet exiting from the discharge end of each of themetal shaping means, at the same uniform rate the improvementcomprising:A. means for simultaneously and continuously sensing thelevel of molten metal in each of said casting units; B. means forgenerating signals representing the molten metal levels continuouslysensed in each of said casting units; C. means for generating a setpoint signal representing the molten metal level desired for all of thecasting units; D. means associated with each of said casting units forcomparing the signal representing the molten metal level sensed for aparticular casting unit with the set point signal representing themolten metal level desired for all of the casting units and forgenerating a signal representing the difference therebetween; and E.means associated with each of said casting units which regulates themolten metal flow to the casting unit in response to the signalrepresenting the difference between the molten metal level sensed forthe particular casting unit and the molten metal level desired so thatthe molten metal levels in all of the casting units are maintained insubstantially the same horizontal plane.
 2. The system of claim 1wherein the metal shaping means is an annular electromagnetic inductorwhich generates an electromagnetic field around a column of molten metalwithin the inductor resulting in an electromagnetic pressure on themolten metal thereby controlling the shape of the molten metal until itsolidifies into its final shape.
 3. The system of claim 1 wherein themeans for sensing the molten metal level comprises a float means.
 4. Thesystem of claim 3 wherein the means for generating a signal representingthe molten metal level sensed is a displacement transducer which isoperatively connected to the float means.
 5. The system of claim 1wherein the means for generating a signal representing the molten metallevel desired is programmed to generate a signal representing anincreasing molten metal level when the molten metal in one of thecasting units reaches a predetermined level.
 6. The system of claim 1wherein the means for generating a signal representing the molten metallevel desired is programmed to generate a signal representing adecreasing molten metal level when the molten metal in one of thecasting units reaches a predetermined level.